Calender for web material



Dec. 23, 1958 B. D. STEWART CALENDER'FOR WEB MATERIAL 5 Sheets-Sheet 1 Filed Nov, 29, 1954 gramme? INVENTOR. 5606'5 fizz-W497 BY QQuq,

Dec. 23, 1958 B. D. STEWART CALENDER FOR WEB MATERIAL 5 Sheets-Sheet 2 Filed NOV. 29, 1954 1 R; INVENTOR. 5/7065 595M494? BY a &

CALENDER FOR WEB MATERIAL Filed Nov. 29, 1954 5 Sheets-Sheet 3 INVENTOR. iucsflxfismeer Dec. 23, 1958 B. D. STEWART CALENDER FOR WEB MATERIAL 5 Sheets-Sheet 4 Filed Nov. 29, 1954 r y MW i 5:. 14-0 Dec. 23, 1958 B. D; STEWART CALENDER FOR WEB MATERIAL 5 Sheets-Sheet 5 Filed Nov. 29, 1954 I IN V EN TOR. v| flaw/:5 fl frirmer United States I Patent O f CALENDER on WEB MATERIAL Bruce D. Stewart, Denville, N. J., assignor to McKiernan- Terry Corporation, Harrison, N. J., a corporation of New Jersey The invention disclosed in. this patent application is a calender for operating on various kinds of web matev rials, and more particularly the resin impregnated kinds.

Heretofore it has been the practice to have separate, single-purpose, two-roll or three-roll machines for frictioning, schreinering and embossing, involving heavy investment, use of much floor space, power equipment for each machine and the frequent waste time of two machineswhen use of onely one machine was required.

The main purpose of the present invention isto avoid such waste and toprovide a single, all-purpose machine capable of well performing all the several operations heretofore accomplished each by only one of the single purpose machines mentioned.

Special objects of the invention are to provide a several purpose machine capable of being quickly and easily converted from one use, to another, enabling it to be used at will for such different operations as frictioning, glazing, rolling, schreinering, embossing and the like.

Generally speaking, these objects have beenattained by the use of two readily mounted and unmounted rolls, usually a top roll and a lower, filled roll, withreadily changeable gearing for effecting proper drive relation between the same and controllablemeans for effecting variable pressure relation between and at times, actual separation of the rolls.

A special feature of the invention is the provision of means, for use in schreinering or like operations, to keep the bottom roll turning after lifting the top roll from rolling engagement-therewith to avoid scuffing the .bottom, filled roll when the two rolls are engaged again.

This possibility of keeping the filled roll turning when out of rolling engagement with the top, driving roll is of special advantage when cooling the rolls for a shutdown, overcoming the, possibility of burning the filled roll from the hot top roll.

Other desirable objects attained by the invention and further novel features and details of the invention are set forth and will appear in the course of the following specification.

The drawings accompanying and forming part of the specification illustrate present practical embodiments of the invention but itwill be appreciated that structure may be modified and changed, all withinthe true intent and scope of the inventionas hereinafter defined and claimed.

Fig. 1 in the drawings is a front end elevation of one of the new combination calendering machines;

Fig. 2 is a broken top plan view of the same;

Fig. 3 is a broken sectional detail illustrating the feature of removing .the roll bearings by a hydraulic jacking arrangement;

Fig. 4 is a broken vertical sectional view of the machine taken on substantially the plane of line 4T4 of Fig. 1;

a Fig. 5' is a broken elevation-of the gearingiconnect- 'ing the'rolls andappearing at the: left in -Figs; 1 and- 2;:

2,865,118 Patented Dec. 23,1958

Fig. 6 is an elevation of the opposite, right-hand end of the machine;

Fig. 7 is an end view showing the gearing equipped with clutch control for schreinering operations, with parts broken and appearing in section;

Fig. 8 is a broken end view of the machine arranged for schreinering service;

Fig. 9 is a broken sectional detail of the clutch as on substantially the plane of line 9-9 of Fig. 7.

Fig. 10 is a fragmentary sectional view showing how the fulcrum pins for the top roll supporting levers maybe carried by eccentric bushings in the upper ends of vertically adjustable supports and how the first idler gear may be journaled onone of these fulcrum pins.

The machine illustrated has but the two rolls, a top, heated roll It) and a bottom, filled roll 11. The top roll is shown as hollow, having a passage 12 therethrough for a gas burner or other heating medium.

A feature of this roll is that it is journaled at opposite ends in self-aligning bearings 13 in levers 14 fulcrumed at their inner ends at 15 and having their outer ends connected by rods 16 with pistons 17 in cylinders 18 pivoted at 19 on the frame 20 of the machine.

With this construction equal or different pressure may be applied to opposite ends of the upper roll by admission of controlled pressure to the upper ends of cylinders 18, orthis roll may be lifted from rolling or pressure applying relation with the lower roll by admission of pressure into the lower ends of the cylinders.

The fulcrums for levers 14 are shown provided by pins 21 engaged in supports in the form of eye-bolts 22 screwed, into the frame, and secured in adjusted rela tion. by lock nuts 23.

The lower roll is shown journaled in the frame in fixed bearings 24.

Drive of the machine is effected in the illustration from a gear reduction electric motor 25 and chain 26 to a sprocket 27 on the inner end of the upper roll shaft.

Drive from the upper roll to the lower roll is effected through a train of gears which can be varied and controlledaccording to results to be accomplished by these rolls.

In the illustration the rolls are shown geared for friction service, with a drive gear 28, Fig. 5, on the end of the top roll shaft in mesh with a first idler 29 and the latter in mesh with a second idler 30 carrying on its face a smaller gear 31 in mesh with the final gear 32 on the end of the lower roll shaft.

The gear 31 on the second idler is shown secured in readily removable relation by through bolts 33, enabling .quick substitution at this point of different gears for different speed ratios.

The first idler 29,. as shown in Fig. 10, is journaled on the extended end portion 34 of the fulcrum pin 21 at.that end of the top roll so that adjustment of the top roll about, this center will not affect the mesh of the first, drive gear and the first idler.

Eccentic bushings SS-for fulcrum pins 21 enablethese pinsto be adjusted in the supporting eye-bolts 22. These adjustments may be utilized for shifting the-levers carrying the top roll tocenter in vertical plane the top roll over the bottom, roll.

- The second idler 30 is shown as mounted for adjustment toward and away from the first idler and on an are taken from the center of the lower roll by being carried by a stub shaft 36, Figs. 5 and 9, secured in an arcuate slot 37 in the frame by lock-nuts 38 and adjusted by screw 39 bearing on pad 40located in the slot in engagement with the shaft. i

The slot 37, as shown in Fig. 5, is accurately finished with its axis the center of the lowerroll shaft 41fso that adjustments of the second or lower idler shaft to'etfect proper mesh of the second with the first idler will not vary the driving relation between the second idler and the lower r011.

In some circumstances where required gear ratios permit, the second idler may mesh direct with the gear on the lower roll shaft, thus reducing the gears to four in number, all in alignment, instead of the five shown, with the last two gears offset from the first three, as indicated in Figs. 1 and 2.

The feed of the cloth is indicated at 42 in Fig. 4, travelling from a roll on the brake shaft 43 about guide and tensioning rollers 44, 45 over an expander 46 between the top and bottom rolls to a take-up roll 47 driven by a windup motor 48.

The shaft 43 is shown controlled by a suitable adjustable brake 49.

The mounting of the top roll in self-aligning bearings in disconnected, independently shiftable lever arms 14 allows for full inspection, adjustment, repair or other servicing and the removal and replacement of different kinds and sizes of top rolls.

This construction also permits of the top roll being swung clear up over and backward, away from the bottom roll, as indicated in the broken lines in Fig. 4. This can be effected simply by disconnecting the supporting levers at 50 from the upper ends of piston rods 16, and then swinging these levers upwardly and away from the bottom roll.

Then the lower roll will be fully exposed and may, if it needs turning down, be turned down, in place, by a lathe attachment located in the machine, in cooperative relation with the roll surface.

The bottom or filled roll, like the top roll, is readily removable for replacement and substitution of different kinds and sizes of rolls.

For such purposes the self-aligning bearings for the rolls may be of the type indicated in Fig. 3, with inner 'race rings 51 which can be expanded by high pressure hydraulic hand pumps or jacks connected by tubing 52 with passages 53, 54 leading through the ends of the roll shafts into spaces beneath said rings.

Then upon removal of a cover plate 55 secured to the end of the shaft and holding the spacer or retainer 56 which holds the race ring in place, and also removal of the outer oil seal cover plate 57, the inner race ring may be expanded by the hydraulic pressure exerted on it to slip off the end of the roll shaft.

Special means may be provided for controlling and maintaining desired roll pressure. Such control may be manual, automatic or semi-automatic.

The independent mounting of the lever arms and the provision of a separate pressure cylinder for each of these arms enables application of either equal or dissimilar pressure to opposite ends of the top roll. Thus different materials may be handled to suit different conditions and requirements.

By substitution and variation of the gearing the rolls may be properly correlated for the various calendering operations usually considered under the headings of frictioning, schreinering and embossing. For rolling engagement operations such as in schreinering, the gear drive from the top to the bottom roll may be disconnected so as to effect direct drive from the top to the lower roll.

When the rolls are separated for jumping a seam or other purposes, it is highly desirable that the lower roll be kept turning so that when the rolls areengaged again there will be no scufiing of the roll surfaces.

Accordingly, for schreinering or like rolling contact operations, the gear train may be made up as illustrated in Figs. 7, 8 and 9, with an interposed clutch to permit free rolling operation of the lower roll while pressure'is on and to drive the lower roll at the top roll speed when the top roll is lifted out of rolling engagement with the .bottom roll. r t

This clutch is shown as disposed between the second idler gear 30 and gear 31 concentric therewith and as consisting of clutch plates 58 for coupling and uncoupling these two gears, shifted by collar 59 engaged by the clutch fork 60.

The latter is shown in Figs. 7 and 8 pivoted at 61 and actuated through connections 62 from a a power cylinder 63, solenoid or equivalent power device.

Hydraulic or pneumatic presure may be employed for actuating'this power cylinder, and generally this would be the same pressure source as used in pressure applying cylinders 18. This enables simplified control and interlocking so that the clutch will be open and the lower roll free to roll with the upper roll when pressure is on and so that the clutch will be closed and the lower roll driven when pressure is off and the upper roll is lifted.

These interlocking connections are indicated diagrammatically in Fig. 8 as comprising piping 64 from the top of pressure cylinder 18 to the top or outer end of clutch cylinder 63, so that with downward force on the piston in the pressure cylinder to apply downward pressure of the top roll there will be pressure on top of the piston in the clutch cylinder to hold the clutch disengaged and the lower roll thus free to turn with the top roll and connections 65 between the lower end of pressure cylinder 18 and the inner end of clutch cylinder 63 to effect closing of the clutch to drive the lower roll through the gears when pressure is applied to lift the top roll from rolling engagement with the botom roll, thus to assure that the bottom roll will be turning at substantially the surface speed of the top roll when the upper roll is again lowered into driving engagement with the bottom roll.

With this arrangement there is minimum wear on the clutch since the clutch is open during the schreinering operation and only comes into service when the top roll is lifted to jump a seam or the like. As the top roll is lowered the clutch is automatically thrown out, it having served its purpose of keeping the lower roll turning while the rolls are separated, automatically relinquishing its action as the rolls are brought back into rolling engagement.

A further important use of the clutch is to keep the bottom roll turning during the cooling-off period at the end of a run to avoid any burning or overheating of sections of the lower, filled roll while the top roll is being given time to cool.

The construction disclosed enables the ready substitution and changing of different rolls and gears for different uses of the machine.

To change from the free wheeling schreinering to the positive drive required for such operations as frictioning and embossing, fixedly connected second idler and gear carried thereby may be substituted for the similar clutch connected gears or, if desired, provision may be made for fixedly pinning or bolting the clutch connected gears together.

Gears necessary to effect different gear ratios can be readily substituted and interchanged.

The first or main drive gear on the end of the top roll has a rolling movement about the first idler in the raising and lowering movements of the arms carrying the top roll and the first idler is journaled on the fulcrum center of the roll lifting arms so these gears remain in constant and correct mesh irrespective of roll adjustments.

The second idler is adjustable on an are about the center of the lower roll and so remains in constant mesh with the lower roll gear irrespective of adjustments toward or away from the first idler for different gear changes or the like. a

The eccentric bushings for the fulcrum pins enable adjustment of the roll carrying arms laterally with respect to the lower roll for centering adjustments of the top roll in respect to the bottom roll.

Thechain. drive to the top roll allows for the normal lifting and lowering movements of that roll and, if desired,

the drive motor may be mounted on a base adjustable to allow for all necessary roll adjustment.

The machine disclosed, while particularly suited to operating on resin finishes and readily convertible to various resin finish processing operations, may well be used for many other web material calendering operations.

While pneumatic power cylinders have been used for applying controlled pressure to opposite ends of the upper roll, it is contemplated that other forms of power devices or a single power unit may be employed for the purpose.

The self-aligning bearings illustrated allow for the necessary limited independent adjustment of the lever arms carrying the top roll but the particular form of such bearings may vary from that shown.

The eye-bolt mountings for the fulcrum pins enable vertical adjustment of the pivotal aXis of the roll supporting lever arms for rolls of different diameter.

The chain drive provides a readily disconnectible form of drive means enabling quick disconnection of the drive roll from the motor or power source when the arms are uncoupled from the power cylinders and lifted to carry the upper roll upward and away from the bowl or filler roll. And while for reasons disclosed the main drive to the top cylinder may be preferred, it is possible that for some purposes the main drive may be by means of gears, chains or belts to a shaft extension of the bottom filled roll at either side of thernachine.

When the top roll is lowered to adjust it to reduced diameter of the lower, filled roll after the latter has been turned down to a lesser diameter, it may be necessary to lower the clutch and the clutch operating cylinder correspondingly. Accordingly, the bracket 66 carrying the clutch shifting lever 60 and the clutch cylinder 63 have been shown in Figs. 7 and 8 both mounted on the same base plate 67 adjustably secured by bolt and slot connections 68 on the .main frame of the machine.

Heretofore in conventional designs of embossing calenders, with gears of the engraved cylinder and filled roll directly meshed to insure correct surface speed, it has been necessary to provide spare pairs of gears for various combinations of engraved cylinders and filled rolls.

The present invention eliminates this need, for with the gear train illustrated in Figs. 5 and 7, only one set of gears is required for any selected type of surface.

Within the limitation of the design, cylinders from ten 6 inches to twelve inches in diameter with filled rolls ranging from twenty to twenty-four inches in diameter, respectively, can be utilized without any change in the original gear train.

What is claimed is:

Calender for web materials comprising a supporting frame, a bottom roll journaled in said frame, a top roll cooperable with said bottom roll, levers fulcrumed at their one ends on said frame at opposite ends of said top roll, independently regulatable power cylinders pivotally connected with the frame and pivotally connected with the opposite ends of said levers, self-aligning bearings on said levers supporting said top roll in the intermediate portions of said levers, fulcrum pins for the fulcrumed ends of said levers, fulcrum supports for said pins, said fulcrum supports carrying said fulcrum pins being vertically adjustable on the frame, eccentric bushings carrying said fulcrum pins and rotatably adjustable on said fulcrum supports for laterally shifting said levers for centering the top roll over the bottom roll, means for driving said top roll, and gearing for driving said bottom roll from said top roll including a gear fixed to said top roll, a first idler gear driven from said top roll gear and journaled on one of said eccentrically adjustable fulcrum pins, a second idler gear journaled on the frame in mesh with said first idler gear and adjustable toward and away from said first idler gear on an are centered on the axis of said bottom roll, and a gear fixed to said bottom roll driven by said second idler gear and whereby drive of the rolls will be unaffected by adjustment of related parts described.

References Cited in the file of this patent UNITED STATES PATENTS 1,535,660 France Apr. 28, 1925 1,637,282 Schlatter July 26, 1927 1,669,798 Wilkinson et al May 15, 1928 1,765,922 Kleinewefers June 24, 1930 1,934,233 Malkin Nov. 7, 1933 1,972,470 Barber Sept. 4, 1934 2,138,397 Cannity Nov. 29, 1938 2,208,688 Stevens July 23, 1940 2,569,034 Auer Sept. 25, 1951 2,686,413 Roubloff et a1 Aug. 17, 1954 2,729,003 Cohn et al. Jan. 3, 1956 2,739,397 Rose Mar. 27, 1956 

